Mazda 5. Manual - part 69

 

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Mazda 5. Manual - part 69

 

 

BODY STRUCTURE [PANEL REPLACEMENT]

09–80B–39

09

CENTER PILLAR REINFORCEMENT AND INNER REMOVAL

DPE098070350B03

1. Rough cut area (A), drill the 9 locations indicated by (B), then remove the center pillar reinforcement.

2. Drill the location indicated by (C) from the bottom, as it cannot be seen from the interior.

95mm

{3.74in}

30mm {1.18in}

(B)9

(A)

 CENTER PILLAR REINFORCEMENT

CUT-AND-JOIN  LOCATION FOR 
CENTER PILLAR REINFORCEMENT

ROUGH CUT LOCATION FOR 
CENTER PILLAR REINFORCEMENT

DPE0980B085

09–80B–40

BODY STRUCTURE [PANEL REPLACEMENT]

3. Rough cut area (D), drill the 6 locations indicated by (B), then pull out the center pillar (inner).

End Of Sie

CENTER PILLAR REINFORCEMENT AND INNER INSTALLATION

DPE098070350B04

1. Make a reinforcement panel using the material from the center pillar (inner) and the center pillar reinforcement.
2. To cut and join the new and existing parts, cut the new part at the specified location shown in the figure, and 

chamfer the joint surfaces of the new and existing parts.

3. When installing the new parts, trial-fit new and existing parts, and then measure and adjust the body to conform 

with standard dimensions.

(E)6

(C)1

160mm

{6.30in}

45mm

{1.77in}

(D)

 CENTER PILLAR (INNER)          

CUT-AND-JOIN  LOCATION FOR 
CENTER PILLAR (INNER)

ROUGH CUT LOCATION FOR 
CENTER PILLAR (INNER)

DPE0980B086

BODY STRUCTURE [PANEL REPLACEMENT]

09–80B–41

09

4. To install the center pillar (inner), trial-fit the new and existing parts, weld the existing parts and the 

reinforcement, and then butt weld the new and existing parts.

5. Because the center pillar reinforcement cannot be welded to the existing parts from the inside of the inner, drill 

2 plug weld holes at the locations indicated by (A) on the existing parts. Install the reinforcement and the 
existing parts by plug welding from the outside, then butt weld the new and existing parts.

Caution

• Press fit the reinforcement panal and the body side material, and then plug weld them.

55mm

35mm

t=1.2mm

L=10mm x 4

140mm

{0.05in}

{1.38in}

{2.17in}

{0.39in}

{5.51in}

6

1

 NEW CENTER PILLAR (INNER)

EXISTING CENTER 
PILLAR (INNER)

CUT-AND-JOIN  LOCATION FOR 
CENTER PILLAR (INNER)

 REINFORCEMENT

DPE0980B088

09–80B–42

BODY STRUCTURE [PANEL REPLACEMENT]

6. Grind the butt welded area with a disc grinder to finish the surface.

End Of Sie

SIDE SILL PANEL (OUTER) REMOVAL

DPE098070270B01

1. Remove the side sill panel (outer).

Caution

• Avoid cutting with a blow torch or similar tools as the insulator (shaded area) is flammable.

2. Remove the spot weld sealer using a disc grinder.

L=10mm x 3

50mm

35mm

t=1.6mm

9

1

(A)2

95mm

{3.74in}

{0.06in}

{0.39in}

{1.38in}

{1.97in}

 CENTER PILLAR REINFORCEMENT

 REINFORCEMENT

 REINFORCEMENT

CUT-AND-JOIN LOCATION FOR CENTER 
PILLAR REINFORCEMENT          

DPE0980B087

 

 

 

 

 

 

 

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